Method for making corrugated board



July 23, 1935.

D. WEBER METHOD FOR MAKING CORRUGATED BOARD 3 Sheets-Sheet 1 Filed Dec. 2, 1935- D. WEBER METHOD FOR MAKING CORRUGATED BOARD July 23, 1935.

Filed Dec. 2, 1935 3 Sheets-Sheet 2 July 23, 1935. I D. WEBER 2,008,974

METHOD FOR MAKING CORRUGATED BOARD Filed Dec. 2, 1955 5 Sheets- Sheet 5 mafia: 200 160 M591- Patented July 23, 1935 UNITED STATES. PAATVTIZENT OFFICE?" MAKING CORRUGATED BOARD METHOD FOR- Davicl Weber. Philadelphia, Pa., assignorlto David Weber and Company, Philadelphia,.Pa., a corporation of Pennsylvania,

Application December 2, 1933, Serial No. 700.735

14 Claims. (Cl. 154-33) I This invention relates to the manufacture of double-walled corrugated paper and has particular relation to double-walled corrugated paper wherein the axes or flutes of the corrugations in one wall are disposed at right-angles with respect to the axes of the corrugations of the other wall.

Up to the present time numerous attempts have been made to manufacture boards and containers comprised of board of the above character on a quantity production basis for commercial use but these attempts have in each instance been unsuccessful.

By the present invention a method and apparatus have been provided to enable relatively inexpensive quantity production of double-walled corrugated sheet of the present character for the commercial market, and it is the objectof this invention to provide 'such a method and apparatus for the manufacture of corrugated sheet of the stated character wherein the axes or flutes of the corrugations of one wall extend at right angles to the axes or flutes of the corrugations "of the cther.

Certain details and features of the invention are set forth hereinafter and disclosed in the accompanying drawings, in which:

Fig. 1 discloses a diagrammatic arrangement of a preferred form of apparatus capable of carrying out the method herein describedto produce the double-walled corrugated paper previously described. Y

Fig. 2 is a fragmentary view in perspective showing one step in the process carried out by the machine disclosed in Fig. 1.

Fig. 3 is a view in perspective of a completed board section as contemplated by the present in-- vention.

Fig. 4 is a diagrammatic view of another form of apparatus capable of carrying out the process herein described.

Fig. 5 is a View in perspective similar to the disclosure in Fig. 2 showing the manner in which the double-walled board is assembled.

Fig. 6 is a view in perspective of'a completed board section similar to the disclosure in 1 ig. 3-

produced by the apparatus disclosed in Fig. i.

Fig. 7 is a diagrammatic arrangement of the machine disclosed in Fig. 1 having in addition means operative to form a third corrugated layer. Fig. 8 is a view in perspective showing a step in the process carried out by the machine disclosed in Fig. "I; and i Fig. 9 is a view in perspective of a completed board section as produced by the disclosure in Fig. 7. 1 Referring now more particularly to the drawings reference numeral l indicates bearing blocks arranged in pairs each of which supports a shaft 5 2 on which are carried supply rolls of paper and straw 3 and 4 respectively, constituting a liner and filler. As shown in Fig. 1 the two sheets of paper 3 and 4 are fed fromthe rolls, and the sheet 4 feeds over idler rolls 5 at each side of a heating plate 6, 10 and between corrug'ating rolls I and 8, where it iscorrugated. An adhesive-containing box 9 is provided with feeding rolls II] which apply paste to the exposed ridges of the corrugations as it passes around the said corrugating roll 8. The other sheet of paper 3 constituting the liner passes around pre-heatin'g rolls and I2 and a pressure K roll [3 by which latter roll the liner 3 is pressed into contact with the exposed ridges of the corrugated paper carried on the previously mentioned roll 8. In this Way the two runs of paper 3 and 4 respectively are joined together to form a singlefaced corrugated sheet A.

As the sheet A emerges from between the rolls 8 and. I3 it passes over a series of elevated rollers M, l5, l6, and I1 respectively and below a roller l8 adjacent which is an adhesive box 19 having suitable rollers 20 associated therewith to apply adhesive to the exposed ridges or corrugations of said sheet A, said sheet A subsequently passing .between opposed rollers 21 and 22 and carried by means of endless belts 23 under a series of rollers 24 which bear on the upper side of said paper. Under therollers 24 are placed a group of hot plates 25 and in each case the paper is pressed against these plates by saidrollers 24. The paper then passes between a pair of opposed rolls 26 and 21 respectively, the upper one of which is provided with an adjustable blade 28 for trans versely severing the continuously moving sheet of single-faced corrugated paper A at predetermiridequal intervals. It will be obvious, however, that in place of the roller cut-off shown and described, a travelling knife or any other type of cut-off means may be employed within the spirit of the invention. So far I have described a machine that is adapted for making a single run of single-faced corrugated paper and that portion of the machine that is adapted to make the second wall of the double-walled corrugated paper is shown in Fig. 1 to the left of the rollers 2| and 22 and consists in part of a table, or platform 29, the upper surface of which is substantially co-planar with the exposed ridges of the single-faced corrugated paper A passing between said rollers 2| and 22 and the hot plates 25 and rollers 24. In the present instance a pair of shafts and 3| are mounted below the table or platform 29 and these shafts are provided with sprockets 32 and 33 respectively about which pass endless belts or chains 34, each having a number of slats secured thereto in predetermined spaced relation. The table or platform29 is provided with longitudinally extending slats therein (not shown) to permit the slats 35 to project above the plane of the platform 29 during travel of the chains 34 in their upper course in the direction of travel,

of the sheet A.

The table or platform 29 is adapted to support a stack 36 of single-walled, double-faced corrugated sheets B of predetermined dimensions having the axes or flutes of their corrugations extending parallel to the longitudinal axis of the machine and at right-angles to the transversely disposed axes or flutes of the corrugations of the single-faced paper A. It is pointed out at this time that the dimensions of the sheets B in the stack 36 on the table 29 should preferably be the same as the dimensions of the sections ar ranged to be cut from the single-faced corrugated sheet A'by the cut-off 28 but may be otherwise, and further the slats 35 on the chain 34 should be so spaced with respect to each other and of such height as to engage only the lowermost sheet B of the stack 36 and move the same to the right of the platform with respect to Fig. 1.

A pair of belts 31 and 38 are respectively mounted each upon a series of pulleys 39 and 40 intermediate the platform 29 and the rollers 2| and 22, for travel in the direction of arrows said belts being arranged so that their adjacent courses are substantially co-planar with the upper plane sur-' face of said platform 29. The belts 31 and 38 just described are arranged to travel at a speed greater than the speed of travel of the chain or belt 34 as well as the linear speed of travel of the single-faced corrugated sheet A, and this enables the successive sheets .3 displaced from the bottom of the stacks 36 by means of the slats 35 on chains 34 to be carried by said belts 31 and 38 into abutting relation. with the next preceding sheet B traveling through the machine.

In the present instance the belt or chain 34 and the belts 31 and 38 aredriven from a .gear 4| on the shaft of the roller 22 by means of belts 42 and 43 respectively, the gear 4| and the roller 22 in turn being driven by a belt 44 from a gear- 45, which is in turn driven by means of a motor 46 through a. belt 41. The roller cut-off. mechanism is likewise driven from the gear by means of a belt 48. In this manner it will'be noticed that all of the operative mechanisms hereinbefore described are driven from a common motor and accordingly each mechanism is thus driven in predetermined timed relation with respect to each of the other mechanisms of the machine. The respective ratios of the gears 4| and 39, ef-

fecting drive of the belts 31 and 38 are such that the linear speed of travel of the belts 31 and 38 will be somewhat in excess of the linear travel of the chains or belts 34 and the single-faced corrugated sheets A, as previously described.

The space between the adjacent courses of the belts 31 and 38 is preferably greater than the thickness of the boards B for the purpose of permitting relative slip of said belts with respect to the surfaces of the boards after the belts have fulfilled their purpose and placed each board into abutment with the next preceding board.

But the space should not be so great as to preclude the belts functioning to move the successive boards into abutting relation with the preceding board. I

The successively abutting sheets B positioned parallel and contiguous to the exposed corrugations of the single-faced sheet A pass between the rolls 2| and 22, the sheets'B being secured to said corrugations by means of the adhesive deposited thereon by the rollers 29 of the paste box I9. The single-faced sheet of corrugated paper and the superimposed sheets B thus have their corrugations at right-angles with respect to each other and these now.contiguous joined sheets are carried as one in the relation shown in Fig. 2 under the rollers 24 over the hot plates 25 toward the cut-off mechanism which severs sections of the sheet A transversely thereof to produce an integral double-walled sheet of corrugated paper the axes of the corrugations of each wall thereof being disposed at right angles with respect to the other as shown in Fig. 3.

It is pointed out at this time that while it may be preferable to sever the sections of the double- Walled sheet formed in the previous manner on the line of abutment of the successive sheets B secured thereto, it is -within the contemplation of this invention that sections of board may be cut from the sheet at alternate lines of abutment thereof or at every third line of abutment and so forth, depending upon the relative size of the finished section desired for purposes of manufacture of containers, boxes, and like articles, and the invention is not further detracted from by the fact that sections of board may be cut from the sheet transversely thereof on a line not coincident with theline of abutment of the sheets B.

In Fig. .4 is shown a modified arrangement of the apparatus disclosed in Fig. 1 of the drawings, the essential difference being that the single-faced corrugated sheet A is fed from below the platform 29 with the exposed ridges or.

corrugations at the upper side thereof rather than at the under side as in said Fig. 1. In this latter arrangement the relative positions of the rollers 24 and heating plates 25 have been inverted. The preformed double-faced sheets B are fed from the stack 35 to overlie the sheet A and are pressed by means of a roller 22a into contact with the exposed corrugations of the sheet A which has been previously applied with adhesive from a paste box |9a by means of rollers 29a. The mechanism for feeding the sheets B is substantially the same as that described in connection with the apparatus disclosed in Fig. 1.

It will be obvious that while the invention disclosed has been limited solely to the manufacture of double-walled corrugated board, exactly the same method and apparatus herein set forth may be employed for the manufacture of plyboard having three, four or more wall thicknesses,

.- and referring particularly toFig. 7 of the drawings an arrangement is shown whereby corrugated board having at least three wall thicknesses or plies may be fabricated. The machine shown inFlg. 7 is the same as that shown in Fig. 1

being disposed adjacent said drum and having rollers to apply adhesive to the exposed ridges .of the corrugations as they pass by on the drum beneath the rolls 3 and 4 comprised in the sheet A, by means of rolls 59. The sheet C then passes about a roll and an adhesive box 6i is provided adjacent said roll to apply adhesive to the exposed ridges of the corrugations of said sheet. The sheet C is then passed about the roller 4i and pressed into contact with the under surface of the successively fed sheets B in a manner similar to'that disclosed in Fig. 4.

The-function of the mechanism operable to feed the sheets B of double-lined corrugated board from the stack 36 as well as that of the rolls 24, heaters 25 and the cut-01f mechanism is the same throughout all of the ramifications of the invention and in this modification the said sheets B are fed so that the axes or flutes of the corrugations thereof are at right angles to the axes or flutes of the corrugations of both of the sheets A and C, the axes or flutes of the corrugations of the latter sheets being substantially parallel with respect to each other.

It is pointed out that while it is preferable from the practicalvviewpoint to carry out the process of the present invention in accordance with the preceding description where'n the axes of the corrugations of the superimposed sheets are disposed at right-angles with respect to each other, it is also within the contemplation of this invention that the axes of the corrugations -of the successively fed sheets B need not be limited specifically to positions at right-angles to the axes of the corrugations of the continuously fed liner and substantially the same result may be attained so long as the axes of the corrugations of said sheets B are disposed at a substantial angle with respect to the corrugations of the sheet A.

The present invention provides the commercial market in this particular field with a corrugated board which is substantially rigid and is of much greater strength than a board where the longitudinal axes of the two corrugated layers or walls are substantially parallel to each other, the latter board will flex under no great strain and if distorted sufiiciently will crack along the axes of said corrugations whereas aboard manufactured in the manner contemplated by this invention wherein the axes of the respective corrugated walls are at right-angles with respect to each other is of an extremely rigid nature, and this characteristic rigidity is not lost in instances wherein the axes of the respec-., tive corrugated sheets A and B are disposed at substantial angles of less than ninety degrees with respect to eachother as set forth above.

While two forms of apparatus for carrying out" the process of manufacture of the present type of board have been disclosed the same may be carried out by still other machines or manually and it is not contemplated by this invention to limit the manufacture of the present board by the specific means disclosed in the drawings, within the scope of the annexed claims.

What I claim is: J

1. The method of making double-walled corrugated board consisting of applying paste to the exposed ridges of a continuously fed single-faced corrugated board, successively feeding preformed sheets of double-faced corrugated board into parallel contact with the last mentioned ridges so that the axes of the, corrugations of the former extend at right-angles to the axes ..of the corrugations of the latter, pressing the double-faced boards and the single-faced run together, and'heating and drying the same.

2. The method of making double-walled corrugated board consisting of applying paste to the exposed ridges of a continuously fed single-. faced corrugated board, successively feeding preformed sheets of double-faced corrugated board into parallel contact with the last mentioned ridges so that the axes of the corrugations of the former extend at right-angles to the axes of the,

corrugations of the latter,pressing the doublefaced boards and the single-faced run together, heating and drying the same, and subsequently cutting sections of board from the run, transversely thereof at predetermined spaced intervals.

3. The method of making double-walled corrugated board consisting of applying paste to the exposed ridges of a continuously fed single-faced corrugated board, successively feeding pre-formed sheets of double-faced corrugated board into parallel contact with the last mentioned ridges so that the axes of the corrugations of the former extend at right-angles to the axes of the corrugations of the latter, pressing the double-faced boards and the single-faced run together, heating and dryng the same, and subsequently cutting sections of board from the run transversely thereof on a line between sheets of said doublefaced board.

4. The method of making double-walled corrugated board consisting of applying paste to the exposed ridges of a continuously fed single-faced corrugated board, successively feeding preformed sheets of double-faced corrugated board end to end into parallel contact with the lastmentioned ridges so that the axes of the cor-. rugations of the former extend at right-angles to the axes of the corrugations of the latter, pressing the double-faced boards and the singlefaced run together, heating and'drying' the same,

and subsequently cutting sections .of boards from the run transversely thereof on the line of abut- 'ment of sheets of said double-faced board.

5. The method of making double-walled corrugated board, consisting of corrugating a continuously fed filler sheet, applying paste to the ridges of said corrugations at one side thereof, joininga continuously fed liner therewith,.applyint; paste to the ridges of the corrugations at the other side of said filler, successively feeding preformed abutting double-faced sheets of corrugated board into parallel contact with the last-mentioned ridges so that the axes of the corrugations of the former extend at right-angles to the corrugations of the latter, pressing the doublefaced board and the single-faced run together, heating and drying the same, and subsequently cutting sections from the board transversely thereof at predetermined spaced intervals.

6. The method of making double-walled corrugated board, consisting of corrugating a continuously fed filler sheet, applying paste to the ridges of said corrugations at one side thereof, joining a continuously fed liner therewith, applying paste to the ridges of the corrugations at the other side of said filler, successively feeding preformed abutting double-faced sheets of corrugated board into parallel contact with the lastmentioned ridges so that the axes of the corrugations of the former extend at right-angles to the corrugations of the latter, pressing the double-faced board and the single-faced run together, heating and drying the same, and subsequently cutting sections from the board transting relation into parallel contact with the lastmentioned ridges of each of said corrugated sheets so that the axes thereof extend at rightangles to the corrugations of said double-faced sheets. 1

8. The method of making double-walled corrugated board, consisting of corrugating a continuously fed filler sheet, applying paste'to the,

ridges of said corrugations at one side of each thereof, joining a continuously fed liner therewith, applying paste to the exposed ridges of the corrugations at the other side of each of said filler sheets, successively feeding pre-formed abutting double-faced sheets of corrugated board into parallel contact with the last-mentioned ridges of each of said sheets so that the axes of the corrugations of the former extend atrightangles'to the corrugations of the latter, pressing the double-faced board and the single-faced runs together, heating and drying the same, and subsequently cutting sections from the board transverselythereof at predetermined spaced inter- Vals. y

9. The method of making double walled corrugated board consisting of successively feeding pre-formed faced sheets of corrugated board into parallel contact with a continuously fed run of faced corrugated board, the axes of the corrugations of said sheets and the continuous run being respectively at right-angles to each other, and adhesive having been applied to the contacting portions of the sheets and the run so that the same may be secured together.

10. The method of making double walled corrugated" board consisting of successively feeding pre-formed faced sheets of corrugated board into parallel abutting contact with a continuously fed run of faced corrugated board, the axes of the corrugations of said sheets and continuous run being respectively at right-angles to each other, adhesive having been applied to the contacting portions of the sheets and the run so that the same may be secured together, pressing said sheets and said run together, and heating and drying the same.

11. The method of making double walled cor rugated board, consisting of applying paste to the exposed ridges of a continuously fed single faced corrugated board, successively feeding pre- ;formed sheets of double faced corrugated board into parallel contact with the last mentioned ridges so that the axis of the corrugations of the former are disposed at an angle with respect to the axis of the corrugations of the latter, pressing the double, faced boards and the single faced run together,- and heating and drying the same.

12. The method of making corrugated board having a plurality of wall thicknesses, consisting of corrugating a plurality of continuously fed filler sheets, applying paste to the ridges of said corrugations at one side-of each thereof, joining a continuously fed liner thereto, applying adhesive to the exposed ridges of the corrugations at the other side of each of said filler sheets and successively feeding pro-formed double faced sheets of corrugated board in abutting relation into parallel contact with the last mentioned ridges of each of said corrugated sheets so that the axes thereof are disposed at an angle with respect to the corrugations of said double faced sheets; I

13. The method of making double walled corrugated board, consisting of feeding pre-formed faced sheets of corrugated board into parallel contact with a continuously fed run of faced corrugated board, the axes of the corrugations of said sheets being disposed at an angle with respect to the axes ofthe continuous run, and adhesive having been applied to the contacting portions of the sheets and the run so that the same may be secured together.

14. The method of making double walled corrugated board, consisting of feeding pre-formed faced sheets of corrugated board'into parallel contact with a continuously fed run of faced corrugated board, the axes of the corrugations of said sheets being disposed at an angle with respect to the axes of the continuous run, and adhesive having been applied to the contacting portions of the sheets and the run so that the same may be secured together, and heating and drying the same.

' DAVID WEBER. 

